• Kohler Decision Maker 550 Manual
• Decision Maker 3+ Manual

Summary of Contents of user manual for Kohler 20-3250 kW. Operation Industrial Generator Sets Models: 20-3250 kW Controllers: Decision-Makerr 550 Software (Code) Version 2.10 or higher TP-6200 10/12i.

California Proposition 65 WARNING Engine exhaust from this product contains chemicals known to the State of California to cause. Table of Contents Product Identification Information. Table of Contents, continued 2.7.13 Menu 13—Communications. Table of Contents, continued 3.12 Detroit Diesel Engine Control Systems. Notes 6 TP-6200 10/12.

Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting Electromechanical equipment, WARNING including generator sets, transfer switches, switchgear,. Battery gases. Explosion can cause Servicing the fuel system. A flash Carbon monoxide symptoms. Severe injury or death. Battery gases.

The fuel system. Explosive fuel Gas fuel leaks. Explosive fuel Hazardous Voltage/ vapors can cause severe injury or vapors can. High voltage test.

Hazardous Servicing the day tank. Hazardous Testing live electrical circuits. Voltage can cause severe injury or voltage. Hot Parts Notice WARNING NOTICE This generator set has been rewired from its nameplate voltage to Hot coolant and steam. Notes 12 Safety Precautions and Instructions TP-6200 10/12. Introduction This manual provides operation instructions for 20 kW Abbreviations and larger generator sets equipped with the following controller. Service Assistance For professional advice on generator set power China requirements and conscientious service, please contact North China Regional Office.

Section 1 Specifications and Features 1.1 Introduction The controller features, accessories, and menu displays depend upon the engine electronic. 1 2 3 4 5 6 TP-6083-2 8 7 1. Generator set master switch, run/off-reset/auto positions 5. Digital display. System Warning. Yellow lamp identifies an existing System Shutdown.

Red lamp indicates that the fault condition that does not shut. 1.2.2 Digital Display and Keypad Figure 1-5 illustrates the digital display and keypad. Note: Press any key on the keypad. Engine Displays (Menu 2) Event History displays up to 100 stored system events including status, warnings, and shutdowns. 1.2.3 Switches and Controls The generator set master switch with the keyswitch option (Figure 1-7) is available to meet appropriate. 1.2.4 Controller Circuit Boards 1.2.5 Fuses The controller has five circuit boards—indicator, AC Circuit Fuses (TB5).

Fuses are located inside. Figure 1-10 shows locations of the terminal strips on the 1.2.7 Circuit Board Interconnections for controller interconnection circuit board. 1.2.8 Communication Ports 1.3 Controller Logic Specifications The main logic circuit board contains several The controller logic specifications section is. Factory-Defined Settings Relay Inhibit Refer Driver Time Time Status Event to Output Alarm Default Delay Delay or Fault Menu Digital.

Factory-Defined Settings Relay Inhibit Refer Driver Time Time Status Event to Output Alarm Default Delay Delay or Fault Menu Digital. Factory-Defined Settings Relay Inhibit Refer Driver Time Time Status Event to Output Alarm Default Delay Delay or Fault Menu Digital. Factory-Defined Settings Relay Inhibit Refer Driver Time Time Status Event to Output Alarm Default Delay Delay or Fault Menu Digital. Factory-Defined Settings Relay Inhibit Refer Driver Time Time Status Event to Output Alarm Default Delay Delay or Fault Menu Digital. Factory-Defined Settings Relay Inhibit Refer Driver Time Time Status Event to Output Alarm Default Delay Delay or Fault Menu Digital. Factory-Defined Settings Relay Inhibit Refer Driver Time Time Status Event to Output Alarm Default Delay Delay or Fault Menu Digital.

Engine speed recovery depends upon characteristics Regulator Gain. Regulator gain refers to the gain of the such as engine make. Notes 32 Section 1 Specifications and Features TP-6200 10/12. Section 2 Operation 2.1 Prestart Checklist Fuel Level.

Check the fuel level and keep the tank(s) full to ensure. Auto Starting Run Time Feature Move the generator set master switch to the AUTO The run time feature allows the. 2.3.2 Stopping (User Stopping and See Section 2.8.8, Menu 8—Time Delays, for Fault Shutdown) information on how to enable the. Note: Text shown in italics in this manual represents Emergency Power System (EPS) Supplying Load. Digital display messages. When the generator set frequency drops to less than NFPA 110 Fault.

The lamp illuminates and the alarm 59 Hz. 2.3.6 System Shutdown Lamp Defined Common Faults. The lamp illuminates and the unit shuts down when one or more of. High Oil Temperature. The lamp illuminates and the Low Fuel (Pressure) Shutdown. The lamp illuminates unit shuts down because of.

Over Current VR Shutdown. The lamp illuminates and Overvoltage the unit shuts down when the controller detects an Overvoltage Time. 2.3.7 Controller Resetting (Following 8.

Move the generator set master switch to the AUTO System Shutdown or Warning) position. Specific Applications Waukesha- with Menu 15 DDC/MTU Other Input Non-ECM Powered (Paralleling Engine with Specialized Type ECM Engine Engine. Menu List Summary (Legend: D First level submenu, d second level submenu) Menu 1 Menu 2 Menu 2 Menu 4.

Menu List Summary, continued (Legend: D First level submenu, d second level submenu) Menu 7 Menu 9 Menu 9 Menu. Menu List Summary, continued (Legend: D First level submenu, d second level submenu) Menu 10 Menu 10 Menu 11 Menu.

Menu List Summary, continued (Legend: D First level submenu, d second level submenu) Menu 13 Menu 14 Menu 20 Menu. 2.5 Reviewing Digital Display Enter ↵ Key. Press the enter ↵ key to confirm the entered information on the display. 2.5.2 Auto-Scroll Function Error Messages The auto-scroll function continuously shows voltage and When an error message appears, the entered current. D Fixed Voltage when entry is beyond the range of Range Error appears when the user attempts to enter: limited. 2.6.1 PC Communications Local Area Network (LAN) There are four ways to communicate between a PC and A PC connects.

Remote Single Connection network. Acceptable devices include the Decision- Makerr 550 controller, Decision-Makerr 340 controller, A modem connects a PC.

2.7 Reviewing Menu Displays See Section 2.5.3, Request and Error Messages, for error display messages and explanations while Use this. 2.7.1 Menu 1—Generator Monitoring Note: For the auto-scroll function, press ENTER at V & A Summary menu. Press the Reset. Menu 1—Generator Monitoring, continued Menu 1 Overview (Single-Phase Connections) MENU 1 GENERATOR MONITORING VOLTS & AMPS → V & A. 2.7.2 Menu 2—Engine Monitoring Menu 2 displays engine operating data including oil pressure and temperature, coolant pressure and temperature, fuel. Menu 2 Overview MENU 2 ENGINE MONITORING (MDEC/ADEC-Equipped Engines only) ENGINE MONITORING → ENGINE MONITORING → BASIC DETAILED OIL PRESSURE.

2.7.3 Menu 3—Analog Monitoring Note: If the analog display shows O/R (out of range), no input is connected or the. 2.7.4 Menu 4—Operational Records After performing maintenance, enter YES to reset records reflecting the current day. The user must enable.

2.7.5 Menu 5—Event History 2.7.7 Menu 7—Generator System Menu 5 stores and displays the times and dates of up to. Menu 7 Overview MENU 7 GENERATOR SYSTEM OPERATING MODE → OPERATING MODE → STANDBY Y/N PRIME POWER Y/N SYSTEM VOLTAGE.

2.7.8 Menu 8—Time Delays If the Cooldown Temperature Override is not enabled, the unit will cease to run when the. 2.7.9 Menu 9—Input Setup continues to run regardless of shutdown signals where potential engine/generator damage can occur. Menu 9 displays. Menu 9 Overview MENU 9 INPUT SETUP SETUP DIGITAL → TO ANALOG INPUT AUXILIARY INPUTS SETUP (NEXT) DIGITAL INPUT 01. 2.7.10 Menu 10—Output Setup The user can select up to 21 user-defined digital status events and faults designated as D01.

Menu 10 Overview, continued Group B.NFPA 110 FAULT Group B, continued For defined system events, choose The 15 NFPA. 2.7.11 Menu 11—Voltage Regulator See Section 2.8.11 to make changes in this menu. Menu 11 displays setup of the voltage. 2.7.12 Menu 12—Calibration The user must enable the programming mode to edit the display.

Menu 12 provides access to the. 2.7.13 Menu 13—Communications Menu 13 shows the settings for remote communications. See Section 2.8.13 to make changes in this menu. 2.7.14 Menu 14—Programming Mode Menu 14 provides local or remote access to the programming function. The user enters a password. 2.7.15 Menu 15—Protective Relays (PR) Menu 15 provides protective relay setup and time delays for units with the paralleling protection.

2.7.16 Menu 20—Factory Setup (Version 2.10) Menu 20 provides factory setup information including the number of operating days, generator set. 2.7.17 Menu 20—Factory Setup Note: For Version 2.69 and lower, enter the numeric (Version 2.21) serial number from the generator. Notes TP-6200 10/12 Section 2 Operation 73. 2.8 Local Programming Mode On All menu displays apply to both single-phase and three-phase voltages unless otherwise noted as (1.

2.8.1 Menu 1—Generator Monitoring Note: For the auto-scroll function, press ENTER at the V & A Summary menu. Menu 1—Generator Monitoring (Three-Phase Connections), continued Menu 1 Displays with Key Entries Key Entry Display Description A L1 L2 L3. Menu 1—Generator Monitoring (Three-Phase Connections), continued Menu 1 Displays with Key Entries Key Entry Display Description L3 KVA # Displays. Menu 1—Generator Monitoring (Single-Phase Connections), continued Menu 1 Displays with Key Entries Key Entry Display Description POWER KW → Displays. 2.8.2 Menu 2—Engine Monitoring Menu 2 provides engine operating data including oil The detailed engine monitoring functions appear only for. Menu 2—Engine Monitoring, continued Menu 2 Displays with Key Entries Key Entry Display Description (DDEC/JDEC/EMS2/EDC3-Equipped Engines only) ENGINE MONITORING →. Menu 2—Engine Monitoring, continued Menu 2 Displays with Key Entries Key Entry Display Description (DDEC/JDEC/EMS2/EDC3-Equipped Engines only, continued) ENGINE MODEL.

Menu 2—Engine Monitoring, continued Menu 2 Displays with Key Entries Key Entry Display Description (MDEC-Equipped Engines only) ENGINE MONITORING →. 2.8.3 Menu 3—Analog Monitoring Menu 3 provides the battery voltage and up to 7 user- midpoint 2.5 volts corresponds to. Menu 3—Analog Monitoring (Non-ECM Engines) Menu 3 Displays with Key Entries Key Entry Display Description ENTER MENU NO. Menu 3—Analog Monitoring (Waukesha Engines) Menu 3 Displays with Key Entries Key Entry Display Description ENTER MENU NO. 2.8.4 Menu 4—Operational Records Menu 4 provides the generator set operational records Generator set connected to an automatic transfer including. Menu 4—Operational Records, continued Menu 4 Displays with Key Entries Key Entry Display Description ENGINE START?

YES→ Press the Enter. 2.8.5 Menu 5—Event History Menu 5 stores and displays the times and dates of up to 100 stored status, warning. 2.8.6 Menu 6—Time and Date Menu 6 sets the clock time and date and internal Note: A change to the.

2.8.7 Menu 7—Generator System Note A:Some alternators have limited voltage and frequency configurations. Inappropriate Menu 7 contains the factory-preset generator. Menu 7—Generator System, continued Menu 7 Displays with Key Entries Key Entry Display Description SYSTEM FREQ # HZ Displays the. Menu 7—Generator System, continued Menu 7 Displays with Key Entries Key Entry Display Description OVERVOLTAGE → Displays the overvoltage setting. Menu 7—Generator System, continued Menu 7 Displays with Key Entries Key Entry Display Description BATTERY VOLTAGE → Displays the battery. Menu 7—Generator System, continued Menu 7 Displays with Key Entries Key Entry Display Description ENABLE VSG YES/NO Displays the variable. Menu 7—Generator System, continued Menu 7 Displays with Key Entries Key Entry Display Description METRIC UNITS Y/N Displays the metric.

2.8.8 Menu 8—Time Delays Menu 8 displays the various time delays for cyclic the generator set to run for the. Menu 8—Time Delays, continued Menu 8 Displays with Key Entries Key Entry Display Description COOLDOWN TEMPERATURE Enter YES to select. 2.8.9 Menu 9—Input Setup D TIme Delay (Shutdown or Warning). The time delay follows the inhibit time delay.

Analog Input Values. The analog input selection Battle Switch/Fault Shutdown Override Switch. The typically requires entering four values: low warning.

Menu 9—Input Setup Menu 9 Displays with Key Entries Key Entry Display Description ENTER MENU NO. 1-15 Input a menu. Menu 9—Input Setup, continued Menu 9 Displays with Key Entries Key Entry Display Description DIGITAL INPUT 01 → Displays the.

Menu 9—Input Setup, continued Menu 9 Displays with Key Entries Key Entry Display Description ANALOG INPUT 01 → SHUTDOWN ENABLED. Menu 9—Input Setup, continued Menu 9 Displays with Key Entries Key Entry Display Description ANALOG INPUT 01 → Displays the. 2.8.10 Menu 10—Output Setup Note: Cannot Change (because the) NFPA is Enabled appears when the user attempts to modify an. Menu 10—Output Setup Menu 10 Displays with Key Entries Key Entry Display Description ENTER MENU NO. 1-15 Input a menu. Menu 10—Output Setup, continued Menu 10 Displays with Key Entries Key Entry Display Description DIGITAL INPUTS → Displays the digital.

Menu 10—Output Setup, continued Menu 10 Displays with Key Entries Key Entry Display Description COMMON FAULT Y/N Indicates whether the. Menu 10—Output Setup, continued Menu 10 Displays with Key Entries Key Entry Display Description COMMON FAULT Y/N Indicates whether the. Menu 10—Output Setup, continued Menu 10 Displays with Key Entries Key Entry Display Description ANALOG INPUTS → Returns the user. Menu 10—Output Setup, continued Menu 10 Displays with Key Entries Key Entry Display Description DIGITAL INPUTS → Displays the digital. Menu 10—Output Setup, continued Menu 10 Displays with Key Entries Key Entry Display Description RELAY DRV OUT 01 Y/N Indicates. Menu 10—Output Setup, continued Menu 10 Displays with Key Entries Key Entry Display Description RELAY DRV OUT 01 Y/N Indicates.

Menu 10—Output Setup, continued Menu 10 Displays with Key Entries— Deactivating the SCRDO Key Entry Display Description ENTER MENU NO. 2.8.11 Menu 11—Voltage Regulator Menu 11 provides the setup of the voltage regulator Analog Voltage Adjust. Analog input A07 is. Menu 11—Voltage Regulator, continued Menu 11 Displays with Key Entries Key Entry Display Description UNDER FREQ UNLOAD → Displays the.

Menu 11—Voltage Regulator, continued Menu 11 Displays with Key Entries Key Entry Display Description REACTIVE DROOP → Displays the reactive. Menu 11—Voltage Regulator, continued Menu 11 Displays with Key Entries Key Entry Display Description REACTIVE DROOP → ENABLED N/Y Returns. Menu 11—Voltage Regulator, continued Menu 11 Displays with Key Entries Key Entry Display Description PF CONTROL → ENABLED N/Y Displays. Menu 11—Voltage Regulator, continued Menu 11 Displays with Key Entries Key Entry Display Description REGULATOR GAIN ADJ Displays the generator. 2.8.12 Menu 12—Calibration inputs A03-A07 where analog inputs A01 and A02 are reserved for the engine coolant temperature A01.

Menu 12—Calibration, continued Menu 12 Displays with Key Entries (Scale AC Analog Inputs) Key Entry Display Description GEN L2-L0 V. Menu 12—Calibration, continued Menu 12 Displays with Key Entries (Scale AC Analog Inputs) Key Entry Display Description GEN L3-L1 V. Menu 12—Calibration, continued Menu 12 Displays with Key Entries (Scale AC Analog Inputs) Key Entry Display Description GEN L3 AMPS. Menu 12—Calibration, continued Menu 12 Displays with Key Entries (Scale Aux. Analog Inputs) No calibration is available for inputs A01-A02. 2.8.13 Menu 13—Communications The user must enable the programming mode to edit the display. Menu 13 enables communication with the.

Menu 13—Communications, continued Menu 13 Displays with Key Entries Key Entry Display Description CONNECTION TYPE → Displays the user-defined connection. Menu 13—Communications, continued Menu 13 Displays with Key Entries Key Entry Display Description BAUD RATE → Press the Enter key. Menu 13—Communications, continued Menu 13 Displays with Key Entries Key Entry Display Description PRIMARY PORT → Press the Enter key. 2.8.14 Menu 14—Programming Mode The user chooses one of three programming modes: Menu 14 allows altering controller data either locally. Menu 14—Programming Mode, continued Menu 14 Displays with Key Entries Key Entry Display Description ENTER MENU NO.

1-15 Input a. 2.8.15 Menu 15—Protective Relays (PR) the generator set personality profile did not include the paralleling option this menu will not. Menu 15—Protective Relays, continued Menu 15 Displays with Key Entries Key Entry Display Description PR UNDERFREQUENCY → Displays the underfrequency. Menu 15—Protective Relays, continued Menu 15 Displays with Key Entries Key Entry Display Description SD OVER POWER → Displays the.

Menu 15—Protective Relays, continued Menu 15 Displays with Key Entries Key Entry Display Description SD OVER CURRENT VR → Displays. 2.8.16 Menu 20—Factory Setup Note: For Version 2.69 and lower, enter the numeric serial number from the generator set nameplate. Menu 20—Factory Setup, continued Menu 20 Displays with Key Entries Key Entry Display Description CONTROLLER SERIAL NO # Displays the. Section 3 Scheduled Maintenance Under normal operating conditions, the generator set’s Disabling the generator set. Accidental starting can alternator.

3.3 Service Schedule Action System—Component Visually Inspect Check Change Clean Test Interval Fuel System Day tank level X X Weekly. Service Schedule, continued Action System—Component Visually Inspect Check Change Clean Test Interval AC Electrical System Controller lamp test X R. 3.4 Alternator Bearing Service Note: The illustration shows a generator set without a fuel/water separator. The valve Have an authorized. 3.5.2 Subbase Fuel Day Tank Electronic Level Sensor Control Module (ECM) An electronic analog float gauge located below the ECM. 3.5.3 Subbase Inner Fuel Tank Alarm Resetting Procedure This kit provides for both audible and visual alarms from Use the. 2 LPG Liquid Withdrawal Operation 1 D Disconnect lead 73A from the fuel solenoid valve.

D Connect lead 73B. ADV-7600B-B Figure 3-10 Gas Fuel Connections Wiring Diagram 144 Section 3 Scheduled Maintenance TP-6200 10/12. Emissions certified models use a single electronic- Note: The 20-40 kW Deutz engine-powered generator controlled pressure regulator (EPR) for both. 3.7.2 Cooling System Component 3.7.4 Procedure to Flush and Clean Inspection Cooling System To prevent generator set shutdown or damage. Replace the pressure cap. Disconnect the generator set engine starting battery(ies), negative (-) lead first. Place the generator set master switch to the RUN Lubrication and Drive Belt Adjustment Procedure position to start the.

Remove excess grease from the bearing pressure Battery acid cleanup. Battery acid can cause severe relief ports. After reconnecting the battery cables, coat the terminals with petroleum jelly, silicon grease, or other 1 2 3 4 nonconductive. 3.11.3 Specific Gravity Check Correction °C °F Use a battery hydrometer to check the specific gravity of 71.1 160 +. 3.12 Detroit Diesel Engine Control 1 Systems Some generator sets equipped with Detroit Diesel engines use a DDEC/MDEC/ADEC system.

3.13 Engine Control Systems Some generator sets use an engine control system. Access the control box inside the generator set. 3.14.3 Fuel System 3. Toggle the generator set master switch to crank the engine two or three revolutions to lubricate. Section 4 General Troubleshooting This section contains generator set troubleshooting, Battle Switch/Fault Shutdown Override Switch.

The diagnostic, and repair. 4.1 General Troubleshooting Chart Trouble Symptoms Section or Publication Does not crank No or low output voltage Exercise run.

Trouble Symptoms TP-6200 10/12 Section or Publication Does not crank No or low output voltage Exercise run time and/or. Trouble Symptoms Section or Publication Does not crank No or low output voltage Exercise run time and/or event records.

4.2 Controller Display and Voltage Regulation Troubleshooting Chart Section or Publication Trouble Symptoms Probable Causes Recommended Actions Reference. Controller. Notes 160 TP-6200 10/12. Section 5 Generator Set Reconnection 5.1 Introduction Disabling the generator set. Accidental starting can cause severe injury or death. 5.2 Voltage Reconnection 6. Go to Menu 7—Generator System and update the voltage information.

See Section 2.8.7, Menu 7— Procedure. Figure 5-1 20-150 kW Permanent Magnet and Wound Field Single-Phase Alternators, ADV-5875A-P TP-6200 10/12 Section 5 Generator Set Reconnection 163. Figure 5-2 20-400 kW Permanent Magnet and 20-60 kW Wound Field Alternators, ADV-5875B-P 164 Section 5 Generator Set Reconnection TP-6200. Figure 5-3 60 (with Oversize Alternator)-400 kW Wound Field Alternators, ADV-5875C-P TP-6200 10/12 Section 5 Generator Set Reconnection 165. Figure 5-4 350 kW and Larger Pilot-Excited, Permanent Magnet Alternator, ADV-5875D-P 166 Section 5 Generator Set Reconnection TP-6200 10/12.

Kohler Decision Maker 550 Manual

Section 6 Accessories 6.1 Accessories and Connections Kit Description Audiovisual Alarm Several accessories help finalize installation, add Common Failure. 6.1.2 Common Failure Relay Kit 6.1.4 Float/Equalize Battery Charger Kit with Alarm Option The common failure relay kit provides one. GM16088A-A Figure 6-6 Controller (Customer) Connection Kit CHARGER MALFUNCTION LV HV CM BATTERY CHARGER ALARM TERMINAL STRIP GM16088A-A Figure.

6.1.5 Ground Fault Annunciation Ground Fault Controller Setup Procedure A relay contact for customer connection indicates a 1. Reconnect battery. Place the controller master switch to the OFF/ g. Press to enter the inhibit time. Entry RESET position. 6.1.7 Low Fuel (Level/Pressure) Switch Some gaseous-fueled models offer a low fuel pressure switch.

The low fuel pressure switch connects. 6.1.9 Remote Emergency Stop Kit 6.1.10 Remote Reset Feature The emergency stop kit allows immediate shutdown of The remote reset. 6.1.11 Remote Serial Annunciator RSA II is an annunciator panel offered in several kit configurations to support Kohler power equipment. System Monitoring LEDs and Functions Generator Common Fault System Running Communication Common Fault Fault and Status Condition LED Ready.

Decision Maker 3+ Manual

Hello All- new here- I am searching for user guide/ manual / information on reprogramming a kohler 550 controller. Our small local volunteer fire department was gifted one from the goobermint, and it came with no manuals, etc. Most of us can handle the diesel end, but it came set up for automatic exercising once a week- turns out it starts at 4 am on friday mornings, and the neighbors are getting a little upset. As a retired sparky, with some PLC experience, I am pretty sure I can handle this with a little information- like: is there a default code to enter, submenus, etc? I need reset the date and time, and the exercise date and time as well. This is a great unit, 10 yrs old, with less than 200 hrs!

Any and all help greatly appreciated! (I know this is not an antique- but I am desperate!) Thanks for being here!